I think the leak is coming from the front of the oil pan. Ugh.

 

Bummer. Do the PCV308 mod first in case it's pressure related, otherwise, drop the oil pan and replace that gasket or possibily even replace the front cover gasket, too.

Tell me that you didn't sand the aluminum front cover!

 

I did lightly sand the front cover with a block and 400 grit. and I did not sand the bottom. But the cover does not appear to be leaking. The oil appears to coming from these three holes that orient the gasket. I did put more RTV than the RAVE suggested.

 

give it some time before ripping it all apart.....seal can expand a little. what oil are you using?

 

Filled with what I had laying around after doing the oil pump job. Some 5w40 and some straight 30w. Drove it til it was hot twice yesterday and noticed the leak when I went to drain that crap out and fill with fresh 15/40 rotella

 

Maybe check the torque on those front bolts/nuts?

 

Checked them and put an extra 1/4 turn on them. didn't help.

 

I'm going to have to go look at my freshly built 4.6...for some reason...my mind remembers those rubber tabs coming through the pan farther.

l'm glad you posted the picture though, l've been looking for that bracket and couldn't find it...but now l know what it looks like!

EDIT: Mine are about 3/16 to a 1/4 sticking through, l used a lucky 8 gasket set, so that could be part of the difference too? But, l'm wondering if maybe you got the rubber tabs cocked in the holes and it's not letting the gasket seat properly. Very strange place for it to leak, if seated properly. If they are not coming through the pan as far as the rest along the pan, l'd loosen pan and try gently pulling them through the pan farther, but gently.

 

PCV mod done?

 

PVC mod done. Did not solve problem. Right on about the nubs not sticking far enough out of the pan. The idiot mechanic (me) that dit the repair got something lined up poorly around the front studs and the gasket was not making a tight seal up there. Shoulda put in bolts like everyone suggested, which I have done now. Leaks gone.